Rotation knobs for surgical instruments

ABSTRACT

A surgical instrument includes a housing having a shaft extending therefrom. The housing includes a nose having a neck and a base that defines a diameter greater than that of the neck. A rotation knob has a distal end defining a first aperture and a proximal end defining a second aperture, the apertures cooperating to define a lumen extending through the rotation knob that is configured to receive the shaft. The first aperture defines a diameter that generally approximates a diameter of the shaft. The rotation knob is transitionable between an at-rest position and a flexed position. In the flexed position, the second aperture is expanded to permit passage of the base of the nose into an interior of the rotation knob. In the at-rest position, the second aperture generally approximates the diameter of the neck to rotatably engage the rotation knob about the nose with the shaft extending therethrough.

BACKGROUND

1. Technical Field

The present disclosure relates to surgical instruments and, moreparticularly, to rotation knobs for surgical instruments havingrotatable end effector assemblies.

2. Background of Related Art

As an alternative to open surgical instruments for use in open surgicalprocedures, many modern surgeons use endoscopic apparatus for remotelyaccessing tissue through smaller openings or incisions. As a directresult thereof, patients tend to benefit from less scarring, fewerinfections, shorter hospital stays, less pain, less restriction ofactivity, and reduced healing time. A typical endoscopic instrumentincludes a housing, an end effector assembly, and a shaftinterconnecting the housing and the end effector assembly. The housingincludes one or more controls that are operable to control the endeffector assembly such that the end effector assembly may be insertedthrough the opening in tissue and into the internal surgical site, whilethe housing remains externally disposed, allowing the surgeon tomanipulate the housing controls to control operation of the end effectorassembly within the internal surgical site.

An endoscopic surgical forceps, for example, includes a plier-like endeffector assembly which relies on mechanical action between its jawmembers to grasp, clamp and constrict vessels or tissue. Energy-basedsurgical forceps utilize both mechanical clamping action and energy,e.g., electrical energy, ultrasonic energy, light energy, thermalenergy, etc., to treat tissue. In some procedures, once the tissue hasbeen treated, the surgeon has to sever the tissue and, as such, manyforceps have been designed which incorporate a knife or blade memberthat effectively severs the tissue after treating the tissue.

The housings of endoscopic surgical forceps typically include a movablehandle for opening and closing the jaw members, a trigger forselectively advancing the knife or blade, and an actuator forcontrolling the supply of energy to the end effector assembly. Further,some handle assemblies incorporate a rotation assembly that is operableto selectively rotate the end effector assembly in order to position theend effector assembly as desired within the internal surgical site.

SUMMARY

As used herein, the term “distal” refers to the portion that is beingdescribed which is further from a user, while the term “proximal” refersto the portion that is being described which is closer to a user.

In accordance with one aspect of the present disclosure, a surgicalinstrument is provided. The surgical instrument includes a housinghaving a shaft extending distally therefrom. The shaft defines alongitudinal axis. The housing includes a nose disposed at a distal endthereof. The nose includes a neck extending distally from the housingand a base disposed at a distal end of the neck. The base defines adiameter that is greater than a diameter of the neck. The surgicalinstrument further includes a rotation knob having a distal end defininga first aperture and a proximal end defining one or more secondapertures. The first aperture defines a diameter that generallyapproximates a diameter of the shaft. The first and second aperturescooperate to define a lumen extending longitudinally through therotation knob. The lumen is configured to receive the shaft. Therotation knob is transitionable between an at-rest position and a flexedposition. In the flexed position, the diameter of the second aperture isexpanded to permit passage of the base of the nose through the secondaperture and into an interior of the rotation knob. In the at-restposition, the second aperture defines a diameter that generallyapproximates the diameter of the neck of the nose to rotatably engagethe proximal end of the rotation knob about the nose with the shaftextending through the lumen of the rotation knob.

In one aspect, the rotation knob includes one or more protrusionsextending into the interior thereof. The protrusion(s) is configured toengage the shaft, e.g., cut-outs defined within the shaft, to engage therotation knob and the shaft to one another.

In another aspect, the rotation knob includes a retaining ringconfigured to bias the rotation knob towards the at-rest position. Theretaining ring may include an interruption defined therein that permitsexpansion of the retaining ring to thereby permit transitioning of therotation knob between the at-rest and flexed positions.

In still another aspect, the rotation knob includes first and secondpairs of proximal support walls. Each pair of proximal support wallscooperates to define one of the second apertures therethrough. In thisconfiguration, the retaining ring may be disposed between the first andsecond pairs of proximal support walls.

In yet another aspect, the rotation knob includes a plurality ofalternating flanges and recesses disposed on the outer peripherythereof. The alternating flanges and recesses are configured tofacilitate grasping and rotating the rotation knob.

In still yet another aspect, an outer distal corner of the base of thenose defines an angled surface configured to facilitate transitioning ofthe rotation knob from the at-rest position to the flexed position topermit passage of the base through the one or more second apertures.

In another aspect, the rotation knob is monolithically formed as asingle component.

In yet another aspect, the housing is formed from first and secondhousing parts. In this configuration, when the rotation knob is engagedabout the nose of the housing, the rotation knob helps maintain theengagement of the first and second housing parts to one another.

In accordance with the present disclosure, another aspect of a surgicalinstrument is provided. The surgical instrument includes a housinghaving a shaft extending distally therefrom. The shaft defines alongitudinal axis. The housing includes a nose disposed at a distal endthereof. The nose includes a neck extending distally from the housingand a base disposed at a distal end of the neck. The base defines adiameter that is greater than a diameter of the neck. The surgicalinstrument further includes a rotation knob. The rotation knob has adistal end defining a first aperture and a plurality of radially-spacedfingers extending proximally from a proximal end of the rotation knob.The fingers each including a radially inwardly-extending tab disposed ata free end thereof. The tabs cooperate with one another to define asecond aperture. The first aperture defines a diameter that generallyapproximates a diameter of the shaft. The first and second aperturescooperate to define a lumen extending longitudinally through therotation knob that is configured to receive the shaft. The rotation knobis transitionable between an at-rest position and a flexed position. Inthe flexed position, the fingers are flexed radially outwardly to expanda diameter of the second aperture to permit passage of the base of thenose through the second aperture and into an interior of the rotationknob. In the at-rest position, the second aperture defines a diameterthat generally approximates the diameter of the neck of the nose torotatably engage the tabs of the fingers of the rotation knob about thenose, with the shaft extending through the lumen of the rotation knob.

In one aspect, the rotation knob includes one or more protrusionsextending into the interior thereof. The protrusion(s) is configured toengage the shaft, e.g., a cut-out defined within the shaft, to engagethe rotation knob and the shaft to one another.

In one aspect, the fingers are biased towards the at-rest position.

In another aspect, the rotation knob is monolithically formed as asingle component.

In yet another aspect, the housing is formed from first and secondhousing parts. In this configuration, when the rotation knob is engagedabout the nose of the housing, the rotation knob helps maintain theengagement of the first and second housing parts to one another.

In accordance with yet another aspect of the present disclosure, asurgical instrument is provided. The surgical instrument includes ahousing and a shaft extending distally from the housing. The shaftdefines a longitudinal axis and extends through an aperture definedwithin a distal surface of the housing. The shaft further includes abushing disposed about the shaft towards a proximal end thereof. Thesurgical instrument further includes a rotation knob. The rotation knobincludes a proximal end, a distal end, and a lumen extendinglongitudinally therethrough that is configured to receive the shaft. Therotation knob defines an internal cavity in communication with the lumenthat is configured to receive the bushing therein. The rotation knobincludes a plurality of radially-spaced fingers extending proximallyfrom a proximal end thereof. The fingers each include a radiallyoutwardly-extending tab disposed at a free end thereof. The tabscooperating to define an outer peripheral diameter. The rotation knob istransitionable between a first at-rest position and a first flexedposition, while the fingers are transitionable between a second at-restposition and a second flexed position. In the first flexed position, therotation knob is flexed to expand a diameter of the lumen to permitpassage of the bushing distally through the lumen and into the internalcavity of the rotation knob. In the first at-rest position, the diameterof the lumen generally approximates a diameter of the shaft to engagethe bushing within the internal cavity. In the second flexed position,the fingers are flexed radially-inwardly such that the fingers arepermitted to pass through the aperture defined within the distal surfaceof the housing. In the second at-rest position, the outer peripheraldiameter defined by the tabs of the fingers is greater than a diameterof the aperture defined through the distal surface of the housing torotatably engage the distal surface of the housing within a slot definedbetween the proximal end of the rotation knob and the tabs of thefingers, with the shaft extending through the lumen of the rotationknob.

In one aspect, the fingers are biased towards the second at-restposition.

In another aspect, the rotation knob is biased towards the first at-restposition.

In still another aspect, the rotation knob includes a plurality ofalternating flanges and recesses disposed on the outer peripherythereof. The alternating flanges and recesses are configured tofacilitate grasping and rotating the rotation knob.

In yet another aspect, the rotation knob and fingers are monolithicallyformed as a single component.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of the present disclosure are described herein withreference to the drawings wherein like reference numerals identifysimilar or identical elements:

FIG. 1 is a perspective view of an endoscopic surgical forcepsconfigured for use in accordance with the present disclosure;

FIG. 2 is a side, cut-away view of a housing of the forceps of FIG. 1;

FIG. 3 is an perspective view of a shaft and an end effector assembly ofthe forceps of FIG. 1 shown with parts separated;

FIG. 4A is a perspective view of one embodiment of a rotation knobconfigured for use with the forceps of FIG. 1;

FIG. 4B is a longitudinal, cross-sectional view of the rotation knob ofFIG. 4A;

FIG. 4C is a transverse, cross-sectional view taken along section line4C-4C of FIG. 4B;

FIG. 4D is a transverse, cross-sectional view taken along section line4D-4D of FIG. 4B;

FIG. 4E is a top view of a retaining ring of the rotation knob of FIG.4A;

FIG. 5A is a side view of a distal end of the shaft of the forceps ofFIG. 1 showing the rotation knob of FIG. 4A sliding proximallytherealong;

FIG. 5B is a side, cut-away view of a distal end of the housing of FIG.2 showing the rotation knob of FIG. 4A flexed outwardly for engagementabout the housing;

FIG. 5C is a side, cut-away view of a distal end of the housing of FIG.2 shown including the rotation knob of FIG. 4A engaged thereon;

FIG. 6 is a side, cut-away view of a distal end of the housing of theforceps of FIG. 1 shown including another embodiment of a rotation knobengaged thereon;

FIG. 7 is a side, cut-away view of a distal end of a housing of anotherembodiment of a forceps, shown including another embodiment of arotation knob engaged thereon;

FIG. 8A is a perspective view of another embodiment of a rotation knobconfigured for use with the forceps of FIG. 1;

FIG. 8B is a perspective view of another embodiment of a rotation knobconfigured for use with the forceps of FIG. 1; and

FIG. 8C is a perspective view of another embodiment of a rotation knobconfigured for use with the forceps of FIG. 1.

DETAILED DESCRIPTION

FIGS. 1-3 show in detail the operating features and inter-cooperatingcomponents of one example of a surgical instrument, forceps 10,configured for use in accordance with the present disclosure. Althoughthe present disclosure is described with exemplary reference to forceps10, the present disclosure is equally applicable for use with any othersuitable surgical instrument having a housing including one or moremechanical and/or electrical controls operable to control and/ormanipulate an end effector assembly of the surgical instrument. For thepurposes herein, forceps 10 is generally described.

Forceps 10 defines a longitudinal axis “X-X” and includes a housing 20,a handle assembly 30, a rotating assembly 70, a trigger assembly 80 andan end effector assembly 90. Forceps 10 further includes a shaft 12having a distal end 14 configured to mechanically engage end effectorassembly 90 and a proximal end 16 that mechanically engages housing 20.Forceps 10 also includes cable 2 that connects forceps 10 to a generator(not shown) or other suitable power source, although forceps 10 mayalternatively be configured as a battery powered instrument. Cable 2includes wires (not shown) extending therethrough that have sufficientlength to extend through shaft 12 in order to provide energy to at leastone of the jaw members 92 and 96 of end effector assembly 90.

With continued reference to FIGS. 1-3, handle assembly 30 includes afixed handle 50 and a movable handle 40. Fixed handle 50 is integrallyassociated with housing 20 and handle 40 is movable relative to fixedhandle 50. Rotating assembly 70, as will be described in greater detailbelow, includes a rotation knob 100 that is rotatable in eitherdirection about longitudinal axis “X-X” to rotate end effector assembly90 about longitudinal axis “X-X.”

End effector assembly 90 is shown attached at a distal end 14 of shaft12 and includes a pair of opposing jaw members 92 and 96. Morespecifically, jaw members 92, 96 are pivotably coupled to shaft 12 viapivot 91. Each jaw member 92, 96 includes an opposed, electricallyconductive tissue sealing surface 93, 97, respectively. End effectorassembly 90 is configured as a bilateral assembly, i.e., where both jawmember 92 and jaw member 96 are movable about pivot 91 relative to oneanother and to shaft 12. However, end effector assembly 90 mayalternatively be configured as a unilateral assembly, i.e., where one ofthe jaw members 92, 96 is fixed relative to shaft 12 and the other jawmember 92, 96 is movable about pivot 91 relative to shaft 12 and thefixed jaw member 92, 96. A knife assembly 98 is disposed within shaft 12and a knife channel 95 is defined within one or both jaw members 92, 96to permit reciprocation of a knife blade 99 therethrough, e.g., viaactivation of trigger 82 of trigger assembly 80, to cut tissue graspedbetween jaw members 92, 96.

Continuing with reference to FIGS. 1-3, housing 20 houses the internalworking components of forceps 10 and is formed from first and secondcooperating housing parts 20a, 20b. Housing halves 20a, 20b may besnap-fit, or otherwise engaged to one another to form housing 20.Movable handle 40 of handle assembly 30 extends into housing 20,ultimately connecting to a drive assembly 32 that, together,mechanically cooperate to impart movement of jaw members 92 and 96between a spaced-apart position and an approximated position to grasptissue between sealing surfaces 93, 97 of jaw members 92, 96,respectively. More specifically, movable handle 40 includes a pair ofdriving flanges 34 that extends upwardly into housing 20 on either sideof drive assembly 32, ultimately pivotably coupling to housing 20 viapivot 35. Driving flanges 34 are received within mandrel 36 of driveassembly 32, which is disposed about proximal end 38 of drive bar 37,while jaw members 92, 96 are pivotably coupled to distal end 39 of drivebar 37. Due to this configuration, upon pivoting of movable handle 40relative to fixed handle 50, driving flanges 34 are pivoted about pivot35, thereby urging mandrel 36 and drive bar 37 to translatelongitudinally along longitudinal axis “X-X” and through shaft 12 topivot jaw members 92, 96 between the spaced-apart and approximatedpositions. As shown in FIG. 1, movable handle 40 is initiallyspaced-apart from fixed handle 50 and, correspondingly, jaw members 92,96 are in the spaced-apart position. Movable handle 40 is depressiblefrom this initial position to a depressed position corresponding to theapproximated position of jaw members 92, 96.

With continued reference to FIGS. 1-3, in conjunction with FIG. 5C,rotation knob 100 is disposed about both proximal end 16 of shaft 12 andnose 22 of housing 20 and, as mentioned above, is rotatable in eitherdirection about longitudinal axis “X-X” to rotate end effector 100 aboutlongitudinal axis “X-X.” Shaft 12 includes a pair of cut-outs 19 definedwithin opposed sides 18 thereof at proximal end 16 of shaft 12 androtation knob 100 includes a pair of protrusions 102 shapedcomplementarily to cut-outs 19 such that, upon positioning of rotationknob 100 about proximal end 16 of shaft 12, protrusions 102 are receivedwithin cut-outs 19 to engage rotation knob 100 and shaft 12 to oneanother. With rotation knob 100 and shaft 12 engaged to one another,rotation knob 100 may be rotated about longitudinal axis “X-X” to effectcorresponding rotation of shaft 12 and end effector assembly 90 aboutlongitudinal axis “X-X.”

Nose 22 of housing 20 is configured to accept proximal end 104 ofrotation knob 100 thereon to permit rotatable coupling of rotation knob100 and housing 20 to one another. Nose 22 of housing 20 includes a neck23 extending distally from body portion 21 of housing 20 and a distalbase 25 disposed at free end 24 of neck 23. Neck 23 defines a reduceddiameter as compared to distal base 25 of nose 22 such that, as will bedescribed below, when proximal end 104 of rotation knob 100 is disposedabout neck 23, rotation knob 100 is retained in fixed longitudinalposition relative to nose 22 between body portion 21 of housing 20 anddistal base 25 of nose 22. The specific features and configuration ofrotation knob 100 and other embodiments of rotation knobs configured foruse with forceps 10 are described in greater detail below.

Turning now to FIGS. 4A-4E and 5A-5C, rotation knob 100 defines agenerally conically-shaped configuration having a minimum diameter atdistal end 106 thereof and a maximum diameter at proximal end 104thereof, although other configurations are also contemplated. Rotationknob 100 includes a shell 110 defining the conically-shapedconfiguration of rotation knob 100 and includes a generally hollowinterior 112, a distal wall 120 defining distal end 106 of rotation knob100, and first and second sets of proximal support walls 130, 140defining proximal end 104 of rotation knob 100. Distal wall 120 definesan aperture 122 therethrough that generally approximates the dimensionsof shaft 12 such that shaft 12 is permitted to pass therethrough. Walls132, 134 of the first set of proximal support walls 130 extend inwardlyfrom opposed sides of shell 110 and each define opposed surface 133,135, respectively. Surfaces 133, 135 may define curvate configurations(or any other suitable configurations) that cooperate to define anaperture 136 therebetween that is substantially aligned with aperture122 defined through distal wall 120. Aperture 136, in its at-restposition, generally approximates the dimensions of neck 23 of nose 22,such that proximal end 104 of rotation knob 100 may be disposed aboutnose 22 of housing 20, as will be described in greater detail below.Walls 142, 144 of the second set of proximal support walls 140 arespaced-apart from walls 132, 134 of the first set of proximal supportwalls 130 to define an annular slot 150 therebetween. Walls 142, 144 ofthe second set of proximal support walls 140, similar to the first setof proximal support walls 130, extend inwardly from opposed sides ofshell 110 and each define an opposed surface 143, 145, respectively,e.g., a curvate surface (although other configurations arecontemplated), that cooperate to define an aperture 146 that issubstantially aligned with apertures 122 and 136. Similar to aperture136, aperture 146, in its at-rest position, generally approximates thedimensions of neck 23 of nose 22, such that proximal end 104 of rotationknob 100 may be rotatably engaged about nose 22 of housing 20, as willbe described in greater detail below. Apertures 122, 136, 146 togethercooperate to define a lumen 160 extending longitudinally though rotationknob 100. Lumen 160 is configured to receive shaft 12 therethrough, thuspermitting rotation knob 100 to be disposed about shaft 12 in asubstantially at-rest position, as will be described below.

With continued reference to FIGS. 4A-4E and 5A-5C, rotation knob 100includes a plurality of alternating flanges 114 and recesses 116annularly disposed about the outer periphery of shell 110 towardsproximal end 104 of rotation knob 100 (although other configurations arecontemplated) to facilitate grasping and rotating rotation knob 100.Rotation knob 100 is monolithically formed as a single component and maybe formed from any suitable material, e.g., biocompatible polymer(s),that provides at least some degree of flexibility to permit engagementof rotation knob 100 about nose 22 of housing 20, as will be describedbelow. Further, shell 110 may be formed from a relatively thin materialto facilitate flexing of shell 110 for engaging (and disengaging)rotation knob 100 about nose 22 of housing 20, while distal wall 120 andthe sets of proximal support walls 130, 140 provide strength and supportto rotation knob 100. Rotation knob 100 may also include a plurality ofcut-outs 118 defined annularly about shell 110 at proximal end 104thereof to provided increase flexibility to shell 110, e.g., tofacilitate the outward-flexing of proximal end 104 of shell 110 suchthat shell 110 may be positioned about nose 22.

Continuing with reference to FIGS. 4A-4E and 5A-5C, shell 110 includes apair of opposed protrusions 102 extending inwardly into hollow interior112 of shell 110 that are configured to engage opposed cut-outs 19defined within shaft 12 to engage rotation knob 100 and shaft 12 to oneanother. Protrusions 102 extend into lumen 160 defined through rotationknob 100 and are longitudinally disposed between distal wall 120 ofrotation knob 100 and first set of proximal support walls 130 ofrotation knob 100. Rotation knob 100 further includes a retaining ring180 housed within annular slot 150 defined between the sets of proximalsupport walls 130, 140. Retaining ring 180 is secured within annularslot 150 via flanges 137, 139 of walls 132, 134 and flanges 147, 149 ofwalls 147, 149, although retaining ring 180 may otherwise be securedwithin annular slot 150 in any suitable fashion, e.g., mechanicalengagement, friction-fitting, adhesion, etc.

As best shown in FIG. 4E, retaining ring 180 is formed from wire in asubstantially ring-shaped configuration defining an interruption 182that provides resilient flexibility to retaining ring 180, e.g., topermit radial expansion and contraction of ring 180. The wire formingretaining ring 180 may define a circular, oval, square, star-shaped, orany other suitable cross-sectional configuration. Alternatively,retaining ring 180 may be formed from any other suitable resilientlyflexible material and/or may define any other suitable configurationthat provides resilient flexibility to retaining ring 180. As will bedescribed below, the resiliently flexible configuration of retainingring 180 biases retaining ring towards an at-rest or contractedcondition that, in turn, biases rotation knob 100 towards an at-rest, orun-flexed position (see FIG. 5C).

Turning now to FIGS. 5A-5C, in conjunction with FIGS. 1 and 4A-4E, theassembly of rotation knob 100 on a surgical instrument, e.g., forceps10, and the use of rotation knob 100 in conjunction with forceps 10 toeffect rotation of end effector assembly 90 is described. As will becomeapparent in view of the following, the configuration of rotation knob100 permits efficient assembly and disassembly of rotation knob 100 onforceps 10 without requiring additional tools for assembly, withoutrequiring multiple components cooperating to form rotation knob 100, andwithout compromising the integrity of rotation knob 100.

Initially, as shown in FIG. 5A, in conjunction with FIGS. 4A-4E,rotation knob 100 is slid proximally over end effector assembly 90 withend effector assembly 90 passing through lumen 160 defined through shell110 of rotation knob 100. As mentioned above, lumen 160 is configured toreceive shaft 12 therethrough such that rotation knob 100 may be easilyslid proximally along shaft 12 towards housing 20. Lumen 160 isconfigured to permit passage of shaft 12 therethrough without requiringsubstantial flexing of rotation knob 100 such that, at this point, shell110 and retaining ring 180 of rotation knob 100 remain disposed in theirrespective at-rest positions (the at-rest position of rotation knob100). Upon reaching proximal end 16 of shaft 12, with rotation knob 100disposed in the at-rest position, rotation knob 100 is inhibited frombeing translated further proximally due to the abutment of the secondset of proximal support walls 140 of rotation knob 100 and distal base25 of nose 22 of housing 20. That is, distal base 25 of nose 22 ofhousing 20 defines a diameter larger than the at-rest diameter of lumen160 of shell 110 of rotation knob 100 such that distal base 25 isinhibited from passing through lumen 160 when rotation knob 100 isdisposed in the at-rest position. Thus, in order to permit passage ofproximal end 104 of rotation knob 100 proximally beyond distal base 25of nose 22 and into position about neck 23 of nose 22, rotation knob 100is must flex from the at-rest position to a flexed position, therebyincreasing the diameter of lumen 160 so as to permit 25 passage ofdistal base 25 of nose 22 therethrough.

As shown in FIG. 5B, in conjunction with FIGS. 4A-4E, in order to permitpassage of rotation knob 100 over distal base 25 of nose 22, proximalend 104 of rotation knob 100 is flexed radially outwardly to expandlumen 160 to a sufficient diameter to permit passage of distal base 25therethrough. That is, proximal end 104 of shell 110 is flexed radiallyoutwardly such that walls 132, 134 of the first set of proximal supportwalls 130 are moved apart from one another and such that walls 142, 144of the second set of proximal support walls 140 are likewise moved apartfrom one another to increase the diameter of apertures 136, 146,respectively, and, thus, the portion of lumen 160 extending throughproximal end 104 of rotation knob 100. Upon outward flexing of proximalend 104 of shell 110, retaining ring 180 is likewise expanded againstits bias to permit expansion of apertures 136, 146. Further, distalouter corner 26 of distal base 25 of nose 22 may define an angledsurface 27 to facilitate outward flexing of shell 110 of rotation knob100 as rotation knob 100 is urged proximally about distal base 25 ofnose 22, e.g., angled surface 27 of distal base 25 permits proximal end104 of rotation knob 100 to cam therealong towards the flexed position.

Rotation knob 100, in this flexed position, is advanced furtherproximally until the first and second sets of proximal support walls130, 140, respectively, of rotation knob 100 are disposed proximally ofdistal base 25 of nose 22 and are positioned adjacent to neck 23 of nose22. In this position, as shown in FIG. 5C, distal base 25 of nose 22 isdisposed within hollow interior 112 of shell 110 longitudinally betweendistal wall 120 and the first set of proximal support walls 130. Uponachieving this position, with distal base 25 no longer disposed betweenthe opposed walls 132, 134 and 142, 144 of first and second sets ofproximal support walls 130, 140, respectively, and under the bias ofretaining ring 180 and shell 110, proximal end 104 of rotation knob 100is returned back towards the at-rest position (wherein apertures 136,146 are returned towards their at-rest diameters) such that walls 132,134 and 142, 144 are approximated, or clamped about neck 23 of nose 22.In this position, proximal end 104 of rotation knob 100 is engaged aboutnose 22 of housing 20, i.e., neck 23 of nose 22 extends throughapertures 136, 146 defined by first and second sets of proximal supportwalls 130, 140, respectively, while distal end 106 of rotation knob 100is disposed about proximal end 16 of shaft 12, i.e., proximal end 16 ofshaft 12 extends through aperture 122 defined through distal wall 120 ofrotation knob 100.

With continued reference to FIG. 5C, in conjunction with FIGS. 4A-4E,rotation knob 100 is retained in substantially fixed longitudinalposition relative to nose 22 due to the positioning of the first andsecond sets of proximal support walls 130, 140, respectively, betweenbody portion 21 of housing 20 and distal base 25 of nose 22 and underthe bias of retaining ring 180 and shell 110. However, although rotationknob 100 is substantially fixed in longitudinal position relative tonose 22 due to the engagement of proximal end 104 of rotation knob 100about neck 23 of nose 22, rotation knob 100 is permitted to rotate aboutlongitudinal axis “X-X” relative to housing 20. The bias of retainingring 180 and shell 110 towards their respective at-rest positions, whichbias first and second sets of proximal support walls 130, 140,respectively, to approximate, or clamp about neck 23 of nose 22 alsohelps maintain the engagement of housing parts 20a, 20b, to one another,i.e., the clamping of rotation knob 100 about nose 22 inhibitssubstantial separation of housing parts 20a, 20b from one another.

In the engaged position, wherein rotation knob 100 is engaged about nose22, protrusions 102 of rotation knob 100, which extend inwardly intohollow interior 112 of shell 110, are biased into engagement withincut-outs 19 defined within shaft 12 to rotatably fix rotation knob 100and shaft 12 to one another. Thus, upon rotation of rotation knob 100relative to housing 20, shaft 12 and end effector assembly 90 aresimilarly rotated relative to housing 20. Further, the bias of retainingring 180 to clamp proximal end 104 of rotation knob 100 about neck 23 ofnose 22 may be sufficient to retain rotation knob 100 and, thus, endeffector assembly 90 in fixed rotational orientation in the absence ofmanipulation of rotation knob 100. Alternatively, neck 23 of nose 22 mayincludes a plurality of notches (not explicitly shown) defined thereinthat correspond to pre-determined intervals of rotation, e.g., 30degrees, 60 degrees, 90 degrees, etc., of end effector assembly 90. Assuch, rotation knob 100 may be incrementally rotated and locked inengagement with each successive notch (not shown) under the bias ofretaining ring 180 and shell 110 to rotate and fix end effector assembly90 in various different rotational positions.

Referring again to FIGS. 4A-4E and 5A-5C, in order to disengagedrotation knob 100 from nose 22 of housing 20 and shaft 12, proximal end104 of shell 110 of rotation knob 100 is flexed radially outwardly tothe flexed position such that walls 132, 134 of the first set ofproximal support walls 130 are moved apart from one another and suchthat walls 142, 144 of the second set of proximal support walls 140 aremoved apart from one another to expand retaining ring 180, thuspermitting expansion of apertures 136, 146. Apertures 136, 146, areexpanded sufficiently so as to permit passage of proximal end 104 ofrotation knob 100 distally over distal base 25 of nose 22 of housing 20to disengage rotation knob 100 from housing 20. Further, upon outwardflexing of shell 110, protrusions 102 are withdrawn from cut-outs 19defined within shaft 12 to disengage shaft 12 and rotation knob 100 fromone another. Once rotation knob 100 has been disengaged from shaft 12and nose 22, rotation knob 100 may be slid distally along shaft 12,ultimately passing over end effector assembly 90 to remove rotation knob100 from forceps 10.

Turning now to FIG. 6, another embodiment of a rotation knob 200configured for use with forceps 10 is shown. Rotation knob 200 issimilar to rotation knob 100 (FIGS. 4A-4E) and defines a generallyconically-shaped configuration, although other configurations are alsocontemplated. Rotation knob 200 is monolithically formed as a singlecomponent and may be formed from any suitable material, e.g.,biocompatible polymer(s), that provides at least some degree offlexibility to permit engagement of rotation knob 100 about nose 22 ofhousing 20. Rotation knob 200, except where specifically contradictedbelow, may include any of the features discussed above with respect torotation knob 100 (FIGS. 4A-4E).

Continuing with reference to FIG. 6, rotation knob 200 includes a shell210 defining the conically-shaped configuration of rotation knob 200 andhaving a generally hollow interior 212, a distal wall 220 definingdistal end 202 of rotation knob 200, a plurality, e.g., four (4),spaced-apart, proximally-extending fingers 230 disposed at proximal end204 of rotation knob 200, and a lumen 214 extending longitudinallythrough shell 210 of rotation knob 200. Shell 210 of rotation knob 200includes a pair of opposed protrusions 260 extending inwardly intohollow interior 212 of shell 210 that are configured to engage opposedcut-outs 19 defined within shaft 12 to engage rotation knob 200 andshaft 12 to one another. Protrusions 260 extend into lumen 214 definedthrough rotation knob 200 and are longitudinally disposed between distalwall 220 and fingers 230 of rotation knob 200.

Each finger 230 of rotation knob 200 includes an inwardly-extending tab240 disposed at a free end 244 thereof. Tabs 240 of fingers 230cooperate to define an aperture 250 through proximal end 204 of rotationknob 200 that, in conjunction with aperture 250 defined through distalwall 220, define lumen 214 extending longitudinally through rotationknob 200. Fingers 230 are formed at least partially from a resilientlyflexible material, thus permitting fingers 230 to flex radiallyoutwardly from an at-rest position to a flexed position, wherein thediameter of aperture 250 is expanded to permit passage of proximal end204 of rotation knob 200 about distal base 25 of nose 22 of housing 20.Fingers 230 are biased towards the at-rest position, wherein thediameter of aperture 250 generally approximates the diameter of shaft12, thus permitting passage of shaft 12 therethrough while fingers 230of rotation knob 200 remain in a substantially at-rest, or un-flexedposition.

In use, rotation knob 200 is first slid proximally over end effectorassembly 90 with end effector assembly 90 passing through lumen 214defined through shell 210 of rotation knob 200. Upon reaching proximalend 16 of shaft 12, with rotation knob 200 still disposed in the at-restposition, rotation knob 200 is inhibited from being translated furtherproximally due to the abutment of tabs 240 of fingers 230 of rotationknob 200 and distal base 25 of nose 22 of housing 20. Thus, in order topermit passage of proximal end 204 of rotation knob 200 proximallybeyond distal base 25 of nose 22 and into position about neck 23 of nose22, fingers 230 are flexed radially outwardly from the at-rest positionto the flexed position, thereby increasing the diameter of aperture 250and, thus, the proximal portion of lumen 214 so as to permit passage ofdistal base 25 of nose 22 therethrough.

Rotation knob 200, in this flexed position, is now permitted to beadvanced further proximally such that tabs 240 of fingers 230 are movedproximally over distal base 25 of nose 22 into position adjacent neck 23of nose 22. In this position, as shown in FIG. 5C, distal base 25 ofnose 22 is disposed within hollow interior 212 of shell 210longitudinally between distal wall 220 and fingers 230. Upon achievingthis position, with distal base 25 no longer disposed between fingers230, fingers 230 are resiliently biased back towards the at-restposition such that tabs 240 are approximated about neck 23 of nose 22and aperture 250 is returned towards its at-rest diameter. In thisposition, with tabs 240 approximated, or clamped about neck 23 of nose22, rotation knob 200 is retained in substantially fixed longitudinalposition relative to nose 22 due to the positioning of tabs 240 offingers 230 between body portion 21 of housing 20 and distal base 25 ofnose 22 under the bias of fingers 230, although rotation knob 200 ispermitted to rotate about longitudinal axis “X-X” relative to housing20. The clamping or bias of fingers 230 about neck 23 of nose 22 alsohelps maintain the engagement of housing parts 20a, 20b of housing 20 toone another, similarly as described about with respect to rotation knob100 (see FIGS. 4A-4E).

In the engaged position, wherein rotation knob 200 is engaged about nose22, protrusions 260 of rotation knob 200 are engaged within cut-outs 19defined within shaft 12 to rotatably fix rotation knob 200 and shaft 12to one another. Thus, upon rotation of rotation knob 200 relative tohousing 20, shaft 12 and end effector assembly 90 are similarly rotatedrelative to housing 20.

In order to disengaged rotation knob 200 from nose 22 of housing 20 andshaft 12, fingers 230 are flexed radially outwardly from the at-restposition back to the flexed position to expand aperture 250 such thattabs 240 of fingers 230 may pass distally over distal base 25 of nose 22of housing 20 to disengage rotation knob 200 from housing 20. Further,upon outward flexing of fingers 230, protrusions 260 are withdrawn fromcut-outs 19 defined within shaft 12 to disengage shaft 12 and rotationknob 200 from one another. Once rotation knob 200 has been disengagedfrom shaft 12 and nose 22, rotation knob 200 may be slid distally alongshaft 12, ultimately passing over end effector assembly 90 to removerotation knob 200 from forceps 10.

With reference to FIG. 7, another embodiment of a rotation knob 300configured to engage a distal end 22′ of a housing 20′ of a surgicalinstrument 10′ is shown. Surgical instrument 10′ may be a forceps, e.g.,a forceps similar to forceps 10 (FIG. 1), or any other suitable surgicalinstrument including an end effector assembly disposed at a distal endof a shaft and a housing at the proximal end of the shaft forcontrolling operation of the end effector assembly. Rotation knob 300 isconfigured for use with a surgical instrument 10′ including a housing20′ having a distal surface 24′ which defines a distal opening 26′therethrough, rather than a distal nose configuration such as thatdescribed above with respect to forceps 10 (FIG. 1). Further, ratherthan having cut-outs defined within the shaft, surgical instrument 10′includes a bushing 36′ engaged about shaft 12′ towards proximal end 16′thereof that is configured to be received within a cavity 312 definedwithin rotation knob 300 to secure rotation knob 300 and shaft 12′ toone another such that rotation knob 300 can be rotated to effect similarrotation of shaft 12′ and the end effector assembly (not shown) thereof.Rotation knob 300, except where specifically contradicted below, mayinclude any of the features discussed above with respect to rotationknob 100 (FIGS. 4A-4E).

Continuing with reference to FIG. 7, rotation knob 300 includes ahousing 310 defining a proximal end 302, a distal end 304, and a lumen306 extending longitudinally therethrough. Lumen 306 is dimensioned toreceive shaft 12′ of surgical instrument 10′ therethrough. Morespecifically, housing 310 includes a distal hub 320 disposed at distalend 304 thereof that defines an aperture 322 therethrough and a pair ofopposed proximal walls 330 that cooperate to define an aperture 332therethrough. Apertures 322, 332 cooperate with one another to definelumen 306 extending longitudinally through housing 310 of rotation knob300. Housing 310 is at least partially formed from a resilientlyflexible material that is transitionable between a first at-restposition and a first flexed position to permit proximal walls 330 to beflexed apart from one another, thereby increasing the diameter ofaperture 332 and, thus, increasing the diameter of the proximal portionof lumen 306. Housing 310 also defines an internal cavity 312 disposedabout lumen 306 that, as mentioned above, is configured to retainbushing 36′ of surgical instrument 10′ therein.

A plurality of spaced-apart fingers 340 extends proximally from proximalend 302 of housing 310. Each finger 340 includes an outwardly-extendingflange 344 disposed at the free end 342 thereof. As a result of thisconfiguration, a slot 350 is defined between flanges 344 of fingers 340and proximal end 302 of housing 310. Fingers 340 are formed at leastpartially from a resiliently flexible material such that fingers 340 maybe flexed radially-inwardly from a second at-rest position, whereinfingers 340 cooperate to define a first outer peripheral diameter, to asecond flexed position, wherein fingers 340 converge towards one anotherto define a reduced outer peripheral diameter. Rotation knob 300,including fingers 340, may be monolithically formed as a singlecomponent.

In use, rotation knob 300 is first slid over the end effector assembly(not shown) of the surgical instrument 10′ and proximally along shaft12′. Upon reaching bushing 36′, proximal end 302 of rotation knob 300 isflexed radially-outwardly from its at-rest position (e.g., the firstat-rest position) to its flexed position (e.g., the first flexedposition) to permit passage of bushing 36′ through lumen 306 and intocavity 312 defined within housing 310. Bushing 36′ is configured to beengaged within housing 310 via friction-fitting (under the resilientbias of housing 310 back to its at-rest position), or other suitableengagement, to engage shaft 12′ and rotation knob 300 to one anothersuch that rotation of rotation knob 300 relative to longitudinal axis“X-X” effects corresponding rotation of shaft 12′ and the end effectorassembly (not shown) about longitudinal axis “X-X.” Once bushing 36′ ispositioned within cavity 312, housing 310 may be released to returnunder bias (or otherwise return) back towards the at-rest position toengage bushing 36′ within cavity 312 of housing 310.

With housing 310 disposed about bushing 36′ of shaft 12′, rotation knob300 may then be engaged to distal end 22′ of housing 20′. In order toengage rotation knob 300 to distal end 22′ of housing 20′, fingers 340are flexed inwardly from their at-rest position (e.g., the secondat-rest position) to their flexed position (e.g., the second flexedposition) to define a reduced outer peripheral diameter that issufficiently small so as to permit passage of fingers 340 through distalopening 26′ formed in distal surface 24′ of housing 310. Upon passingthrough opening 26′, fingers 340 are permitted to resiliently returnback towards their at-rest position, thus engaging distal surface 24′ ofhousing 20′ within slot 350 defined between flanges 344 of fingers 340and proximal end 304 of housing 310. In this engaged position, rotationknob 300 is substantially fixed in longitudinally position relative tohousing 20′, but is permitted to rotate about longitudinal axis “X-X”relative to housing 20′.

Disengagement of rotation knob 300 from housing 20′ and shaft 12′ iseffected in the opposite manner as the engagement described above,namely, fingers 340 are flexed inwardly to the second flexed positionwherein fingers 340 define a reduced outer peripheral diameter, thuspermitting withdrawal of fingers 340 through distal opening 26′ formedin distal surface 24′ of housing 20′. Fingers 340 are then returnedunder bias back towards the second at-rest position. Thereafter, housing310 of rotation knob 300 is flexed outwardly to the first flexedposition to permit bushing 36′ to be translated proximally through theexpanded proximal portion of lumen 306 to remove bushing 36′ from cavity312 of rotation knob 300. Once bushing 36′ has been removed fromrotation knob 300, housing 310 is permitted to return under bias backtowards the first at-rest position. Ultimately, rotation knob 300 isslid distally along shaft 12′ and passed over the end effector assembly(not shown) thereof to remove rotation knob 300 from surgical instrument10′.

Referring now to FIGS. 8A-8C, various configurations of rotation knobs,e.g., rotation knobs 400, 500, 600, are shown. Rotation knobs 400, 500,600 may be configured for use with forceps 10 (FIG. 1), surgicalinstrument 10′ (FIG. 7), or any other suitable surgical instrument,similarly as described above with respect to rotation knobs 100, 200,300 (FIGS. 5A-5C, 6, 7, respectively). Additionally, the ergonomicfeatures of these rotation knobs, or any other suitable ergonomicfeatures, may be incorporated into the rotation knobs described herein.In other words, although specific ergonomic features of rotation knobs100-600 are shown and described herein, rotation knobs 100-600 may beprovided in any suitable size, shape, and/or ergonomic configuration.

Further, it is envisioned that these various different rotation knobs beinterchangeable with one another, thus allowing the user to select adesired rotation knob depending on the surgical procedure to beperformed, the surgeon's preference, or other factors. Thisinterchangeability is facilitated in that the rotation knobs describedherein are easily and efficiently engaged and disengaged from a surgicalinstrument, e.g., forceps 10 (FIG. 1), thus allowing for easy andefficient interchanging of rotation knobs. This configuration providesincreased customization and versatility to a surgical instrument,without requiring a separate instrument that is customized for each userand/or procedure. Such a configuration also permits the rotation knobsto be used as disposable components that can be easily engaged anddisengaged from the reusable components of a particular surgicalinstrument, thus facilitating removal of the first, used rotation knob,sterilization of the reusable components, and reassembly of theinstrument with a second, new rotation knob in preparation for reuse.

With reference to FIG. 8A, rotation knob 400 includes agenerally-cylindrical body 410 having a plurality of flanges 420extending radially outwardly therefrom substantially along the length ofbody 410. Flanges 420 taper distally to proximally and are spaced-apartfrom one another to define a plurality of finger recesses 430therebetween that facilitate grasping and rotation of rotation knob 400.Rotation knob 400 may otherwise be configured similarly to any of therotation knobs described above.

Referring to FIG. 8B, rotation knob 500 includes a pair of spaced-aparthousing members 510, 520 interconnected by a tube segment 530. Housingmembers 510, 520 each define a generally annular configuration having aplurality of flanges 512, 522, respectively, extending radiallyoutwardly therefrom. Flanges 512 are spaced-apart from one another, asare flanges 522, to define a plurality of finger recesses 514, 524,respectively, therebetween. Finger recesses 514, 524 facilitate thegrasping and rotation of rotation knob 500. Rotation knob 500 mayotherwise be configured similarly to any of the rotation knobs describedabove.

As shown in FIG. 8C, rotation knob 600 defines a more spherical-shapedbody 610 and includes a plurality of fingertip-shaped recesses 620defined therein for grasping and rotating rotation knob 600. Rotationknob 600 may otherwise be configured similarly to any of the rotationknobs described above.

From the foregoing and with reference to the various figure drawings,those skilled in the art will appreciate that certain modifications canalso be made to the present disclosure without departing from the scopeof the same. While several embodiments of the disclosure have been shownin the drawings, it is not intended that the disclosure be limitedthereto, as it is intended that the disclosure be as broad in scope asthe art will allow and that the specification be read likewise.Therefore, the above description should not be construed as limiting,but merely as exemplifications of particular embodiments. Those skilledin the art will envision other modifications within the scope and spiritof the claims appended hereto.

What is claimed is:
 1. A surgical instrument, comprising: a housinghaving a shaft extending distally therefrom and defining a longitudinalaxis, the housing including a nose disposed at a distal end thereof, thenose including a neck extending distally from the housing and a basedisposed at a distal end of the neck, the base defining a diametergreater than a diameter of the neck; and a rotation knob having a distalend defining a first aperture and a proximal end defining at least onesecond aperture, the first and second apertures cooperating to define alumen extending longitudinally through the rotation knob that isconfigured to receive the shaft, the rotation knob flexible between anat-rest position and a flexed position, wherein, in the flexed position,the diameter of the second aperture is expanded from a first diameter toa second, larger diameter to permit passage of the base of the nosethrough the second aperture and into an interior of the rotation knob,and wherein, in the at-rest position, the second aperture defines thefirst diameter to rotatably engage the proximal end of the rotation knobabout the nose with the shaft extending through the lumen of therotation knob.
 2. The surgical instrument according to claim 1, whereinthe rotation knob includes at least one protrusion extending into theinterior thereof, the at least one protrusion configured to engage theshaft to engage the rotation knob and the shaft to one another.
 3. Thesurgical instrument according to claim 1, wherein the rotation knobincludes a retaining ring configured to bias the rotation knob towardsthe at-rest position.
 4. The surgical instrument according to claim 1,wherein the retaining ring includes an interruption defined therein topermit expansion of the retaining ring for transitioning the rotationknob between the at-rest and flexed positions.
 5. The surgicalinstrument according to claim 3, wherein the rotation knob includesfirst and second pairs of proximal support walls, each pair of proximalsupport walls cooperating to define one of the at least one secondapertures therethrough.
 6. The surgical instrument according to claim 5,wherein the retaining ring is disposed between the first and secondpairs of proximal support walls.
 7. The surgical instrument according toclaim 1, wherein the rotation knob includes a plurality of alternatingflanges and recesses disposed on the outer periphery thereof, thealternating flanges and recesses configured to facilitate grasping androtating the rotation knob.
 8. The surgical instrument according toclaim 1, wherein an outer distal corner of the base of the nose definesan angled surface configured to facilitate flexing of the rotation knobfrom the at-rest position to the flexed position to permit passage ofthe base through the second aperture.
 9. The surgical instrumentaccording to claim 1, wherein the rotation knob is monolithically formedas a single component.
 10. The surgical instrument according to claim 1,wherein the housing is formed from first and second housing parts andwherein, when engaged about the nose of the housing, the rotation knobhelps maintain the engagement of the first and second housing parts toone another.
 11. A surgical instrument, comprising: a housing having ashaft extending distally therefrom and defining a longitudinal axis, thehousing including a nose disposed at a distal end thereof, the noseincluding a neck extending distally from the housing and a base disposedat a distal end of the neck, the base defining a diameter greater than adiameter of the neck; and a rotation knob having a distal end defining afirst aperture and a plurality of radially-spaced fingers extendingproximally from a proximal end of the rotation knob, the fingers eachincluding a radially inwardly-extending tab disposed at a free endthereof, the tabs cooperating to define a second aperture, the first andsecond apertures cooperating to define a lumen extending longitudinallythrough the rotation knob that is configured to receive the shaft, therotation knob flexible between an at-rest position and a flexedposition, wherein, in the flexed position, the fingers are flexedradially outwardly to expand a diameter of the second aperture from afirst diameter to a second, larger diameter, to permit passage of thebase of the nose through the second aperture and into an interior of therotation knob, and wherein, in the at-rest position, the second aperturedefines the first diameter for rotatably engaging the tabs of thefingers of the rotation knob about the nose with the shaft extendingthrough the lumen of the rotation knob.
 12. The surgical instrumentaccording to claim 11, wherein the rotation knob includes at least oneprotrusion extending into the interior thereof, the at least oneprotrusion configured to engage the shaft to engage the rotation knoband the shaft to one another.
 13. The surgical instrument according toclaim 11, wherein the fingers are biased towards the at-rest position.14. The surgical instrument according to claim 11, wherein the rotationknob is monolithically formed as a single component.
 15. The surgicalinstrument according to claim 11, wherein the housing is formed fromfirst and second housing parts and wherein, when engaged about the noseof the housing, the rotation knob helps maintains the engagement of thefirst and second housing parts to one another.
 16. A surgicalinstrument, comprising: a housing defining a nose at a distal endthereof; a shaft defining a proximal end and a distal end, the proximalend of the shaft rotatably coupled to the housing, the shaft extendingdistally from the nose of the housing; at least one first engagementfeature disposed towards the proximal end of the shaft adjacent the noseof the housing; an end effector assembly disposed at the distal end ofthe shaft and operably coupled to the shaft such that rotation of theshaft effects corresponding rotation of the end effector assembly; and amonolithic rotation knob including a distal portion and a proximalportion, the monolithic rotation knob defining a lumen extendinglongitudinally therethrough configured to receive the shaft, the distalportion of the monolithic rotation knob including at least one secondengagement feature disposed therein, the monolithic rotation knobconfigured to slide proximally about the shaft from a disengagedposition to an engaged position, wherein, upon movement of themonolithic rotation knob from the disengaged position to the engagedposition, the monolithic rotation knob is configured to flex from anat-rest position, wherein a portion of the lumen defines a firstperimeter, to a flexed position, wherein the portion of the lumendefines a second, larger perimeter, and back to the at-rest position,and wherein, in the engaged position, the proximal portion of themonolithic rotation knob is disposed about the nose of the housing andthe at least one second engagement feature is engaged with the at leastone first engagement feature to engage the shaft and the monolithicrotation knob with one another such that rotation of the monolithicrotation knob about the nose of the housing rotates the shaft and theend effector assembly relative to the housing.
 17. The surgicalinstrument according to claim 16, wherein the monolithic rotation knobincludes a plurality of alternating flanges and recesses disposed on theouter periphery thereof, the alternating flanges and recesses configuredto facilitate grasping and rotating the rotation knob.
 18. The surgicalinstrument according to claim 16, wherein the at least one firstengagement feature is a cut-out and wherein the at least one secondengagement feature is a protrusion.